Method of spoiler construction

Abstract

A vehicle spoiler includes a first rigid body part having an external surface contour, a second resiliently deformable foam body part having an external surface contour complementary to the first surface contour, and means for integrally securing the first and second body parts together. Preferably, the deformable foam body part is molded in situ on the rigid body part. A finishing groove extending between adjacent edges of the first external surface contour and the second external surface contour prevents recognition of differences between the materials and processes used to form the first and second body parts and prevents inconsistent transition between the body parts. A method for forming the spoiler includes fabrication of injection molded body shell parts bonded together by a foam material to form a rigid first body section. The rigid body section is then positioned within a molding cavity while foam material is introduced into the cavity and against engagement surfaces on the rigid body part.

What is claimed is: 
     
       1. A process for forming an exterior vehicle panel having a rigid portion and a resiliently deformable portion comprising: fabricating a rigid structural body with a first exterior surface contour having a transitional boundary;   supporting said rigid structural body to enclose a portion of a molding chamber with said transitional boundary facing toward said chamber; and   molding at least one resilient, compressible foam material in situ with a second exterior surface contour complementary to said first exterior surface contour adjacent said transitional boundary;   and prior to said molding step, positioning a removable welting in said molding cavity adjacent said transitional boundary to separate said molding chamber from said transitional boundary of said first exterior surface contour, and removing said welting following said molding step,   thereby providing a cosmetically consistent styling groove at said transitional boundary of said first surface contour despite dimensional tolerance in said first part.   
     
     
       2. The invention as defined in claim 1 wherein said fabricating step includes forming at least one engagement surface on said rigid structural body, and said molding step includes contacting said engagement surface with said at least one resilient, compressible foam material. 
     
     
       3. The invention as defined in claim 2 and further comprising the step of applying an adhesive agent to said at least one engagement surface prior to said molding step. 
     
     
       4. The invention as defined in claim 2 wherein said rigid structural body includes a cavity having peripheral walls and open for communication with said molding chamber and wherein said engagement surface comprises said peripheral walls, and wherein said molding step includes filling said cavity with one of said at least one said resilient, compressible foam material. 
     
     
       5. The invention as defined in claim 4 wherein said open communication is restricted and further comprising the step of curing said foam material, whereby said cured foam material becomes mechanically locked to said rigid body. 
     
     
       6. The invention as defined in claim 2 wherein said molding step includes chemically bonding said foam to said engagement surface. 
     
     
       7. The invention as defined in claim 2 wherein said at least one engagement surface comprises an extended portion of said rigid structural body and wherein said molding step comprises embedding said extending portion in said foam. 
     
     
       8. The invention as defined in claim 2 wherein said forming step comprises forming at least one first engagement surface on said rigid structural body, and forming at least one second engagement surface on said rigid structural body; wherein said rigid structural body includes a cavity having peripheral walls, and wherein said at least one first engagement surface includes said peripheral walls;   wherein said rigid structural body includes an extended portion and wherein said at least one second engagement surface includes said extended portion; and   wherein said molding step comprises filling said cavity with said at least one resiliently compressible foam material and embedding said extended portion in said at least one resiliently compressible foam material.   
     
     
       9. The invention as defined in claim 1 wherein said fabricating step comprises injection molding first and second shell sections having mating edges and joining said mating edges to form an enclosed chamber in at least a portion of said rigid structural body. 
     
     
       10. The invention as defined in claim 9 wherein said fabricating step further comprises filling said chamber with foam material and adhesively bonding said shell sections with said foam material. 
     
     
       11. The invention as defined in claim 1 and further comprising lining the peripheral walls of said molding chamber with a finish coating prior to said molding step. 
     
     
       12. The invention as defined in claim 1 and further comprising, between said fabricating step and said supporting step, the steps of applying a finish coating to said rigid body, and covering said finish coating with a protective cover to seal said finish coating from contact with said foam during said molding step.